Prefabricated concrete building module and a method for the production thereof

ABSTRACT

A prefabricated concrete building module comprises two pre-cast concrete end panels interconnected and interlinked to a pre-cast bridging panel providing a utility channel at at least one corner thereof, the channel aligning with a reinforcement formation on each side edge of each end panel.

FIELD OF THE INVENTION

The present invention relates to a prefabricated concrete building module and method for the production thereof.

The invention has especial reference to the production of such a module formed with one or more channels intended in use for the accommodation of utility supplies.

Further, the invention concerns a prefabricated concrete building module incorporating panels with a high quality surface or surfaces, which require little or no preparation before applying a decorative finish, e.g. paint.

BACKGROUND OF THE INVENTION

It is well known in the art to manufacture a pre-cast concrete panel by forming same in a mould of the desired dimensions for the purpose of creating an element of a combination which can be constructed to form a prefabricated chamber with at least three defining panels, for example two walls and a ceiling/roof. A number of individual chambers may then be assembled and locked together to constitute an apartment for example. Furthermore, such panels, once assembled, need to be either finished or covered with conventional boards or the like which can be finished or covered with finish products, which is costly.

One of the important requirements in any housing is a provision for ease of access for utility supplies, viz. electrical power, water, communication lines etc. Pre-cast concrete panels currently available do not appear to cater for such requirements.

Accordingly, there is a need for an improved pre-fabricated concrete building module, which addresses the needs of prefabricated building and its related construction techniques.

SUMMARY OF THE INVENTION

It is therefore a general object of the present invention to provide an improved prefabricated concrete building module, which addresses the needs of prefabricated building construction techniques.

An advantage of the present invention is that the production of such a module is formed with one or more channels intended in use for the accommodation of utility supplies

Another advantage of the present invention is that the prefabricated concrete building module has substantially blemish-free and smooth surfaces for presentation as an interior finish, which saves all the time and cost associated with the usual interior finishing.

Another advantage of the present invention is that the prefabricated concrete building module has substantially blemish-free and smooth surfaces for presentation as an interior finish.

According to a first aspect of the present invention, there is provided a prefabricated concrete building module comprising at least two pre-cast reinforced concrete end panels, the reinforcement of the panels extending beyond the limits of the panels, a further pre-cast reinforced concrete bridging panel interconnecting the two said end panels, the reinforcements of the end panels and the bridging panel being interlinked, and the bridging panel being rebated at at least one location to provide a channel registering with a part of at least one of the end panels to create a continuous guide adapted for the passage in use of utility supplies.

The inside surfaces of the end panels and the bridging panel are smooth and finished surfaces.

The bridging panel is rebated as in a right-sided notch having two sides extending through the thickness of the bridging panel orthogonally to the plane thereof.

Conveniently, the bridging panel is rebated at a corner and preferably at each corner.

The bridging panel is provided with steel reinforcement in the form of a mesh or a plurality of rebars suitably embedded within the pre-cast concrete.

In like manner, the end panels are provided with embedded reinforcement that may be in the form of a mesh of steel rods or rebars suitably secured together as by welding.

The bridging panel of the module is produced in a manner hereinafter described and is in essence bonded by pre-cast concrete and by the interlinking reinforcements.

According to a second aspect of the invention there is provided a method for the production of the prefabricated concrete building module of the first aspect, including the steps of:

-   -   pre-casting at least two reinforced concrete panels with their         reinforcement extending beyond the concrete along each of two         longitudinal parallel margins thereof;     -   placing the panels in a jig providing a generally horizontal         mould of generally rectilinear open-ended trough form, with the         panels disposed vertically at each end of the mould and         temporarily fixed to the jig, the upper end of each panel         constituting a part of the base of the trough at each end         thereof;     -   securing a former at each open end of the trough in registration         with the panels to close the mould, the formers being shaped to         generate in use a rebate at each corner of the nascent pre-cast         bridging panel;     -   placing a reinforcement structure in the mould;     -   linking the reinforcement structure to the reinforcement of the         prefabricated panels;     -   providing anchor lifting points within the mould;     -   casting concrete into the mould to cover the reinforcement         structure to produce a reinforced bridging panel; and     -   allowing the concrete to set thereby to provide a prefabricated         concrete building module rebated at each corner to provide a         channel.

Conveniently the reinforcement of the prefabricated panels extends beyond the concrete edges in the form of loops. In practice, these loops substantially align with the rebates at the corner of the pre-cast concrete bridging panel to give an elongated guide extending from the upper surface of the panel for the full length of the prefabricated end panels.

In practice, the prefabricated concrete building module of the invention is then removed from the mould jig using suitable lifting apparatus in combination with slings attached to the anchor lifting points. The completed module of the prefabricated end panels and the thus formed pre-cast bridging panel is of generally inverted U-shape.

A number of assemblies of this kind can be arranged and affixed together in the desired pattern to produce domestic or commercial accommodation with living or working areas of suitable size in accordance with requirements.

The prefabricated end panels are conveniently manufactured in horizontal moulds suitably dimensioned and if necessary masked or blanked to give appropriate finishing in terms for example of window or door openings or internal wall surface embossment patterns. The openings/embossments so produced may be of any desired shape and form.

Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:

FIG. 1 is a perspective elevation of a prefabricated concrete building module comprising a pre-cast concrete bridging panel in accordance with the invention in combination with prefabricated reinforced end panels;

FIG. 1 a is a perspective view of a plurality of building modules arranged in a predetermined pattern to produce a part of a building structure;

FIGS. 2, 3, 4, 5 and 6 each show a different design of prefabricated end panel;

FIG. 2 a is a perspective view of a mould for generating a bridging panel of the kind shown in the immediately preceding figures;

FIG. 7 is a perspective view of a mould jig with a reinforcement set just prior to the concrete being cast into the mould; and

FIG. 8 is a perspective view of the prefabricated concrete building module in the process of removal from the mould jig following the casting of the concrete with the end panels bonded to the bridging panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the annexed drawings, the preferred embodiment of the present invention will be herein described for indicative purpose and by no means as of limitation.

Referring now to FIG. 1 there is shown a prefabricated concrete building module 1 including a pre-cast concrete reinforced bridging panel 2 of generally rectangular form with rebates 4 cast in each corner 3 to create a channel formation 6. The building module 1 further includes two prefabricated end panels 8, 10 as shown cemented and tied into the pre-cast concrete bridging panel 2, the panels 8,10 depending orthogonally from each end of the bridging panel 2. As will be explained later, the panels 8, 10 are formed with an internal reinforcing structure 12 which extends beyond the concrete limits of the panels 8, 10 to provide loops 14 on each side of the panels as illustrated.

At at least one corner 3, and as dictated by requirements, there is provided a skeletal elongate quasi-tubular formation 16 produced from rebar material extending at least the full length of the end panel and tied into the loops 14 of the reinforcing structure 12 of four (4) co-adjacent modules 1, as seen in FIG. 1 a.

Turning now more specifically to FIG. 1 a there is illustrated an assembly 20 of building modules 1 with six such modules 1 forming a ground floor 22, or indeed a basement, with one module 1 shown supermounted on the relatively lower modules 1. The openings formed by the rebates 4 from four (4), or two (2), ca-adjacent modules 1, through which the elongated rebars from a quasi-tubular formation 16 extend, are typically temporarily and releasably closed off by forming plates (similar to the one indicated by reference numeral 23) mounted on the internal surfaces of the end panels 8, 10, in order to enable pouring of concrete therein to form structural columns securing all co-adjacent modules together and with all the superimposed ones, and therefore the overall building. It will be noted that the end panels 8, 10 are provided with customized finishing in the form of differing apertured/embossed formations, such as a portal 24, a window 26, an internal doorway 28, door/window frames 29, baseboards 31 and the like to afford the various aspects normally associated with living or commercial premises. The end panels 8, 10 may also selectively be provided with rebates as at 30 for the introduction of utilities at floor level, for example for under floor heating elements or tubing (not shown), or any other utility supplies such as electricity, water, telephone etc., the relevant cables/pipes (not shown) being fed there through, to their places of use.

FIGS. 2 to 6 illustrate the differing apertured/embossed formations hereinbefore mentioned and as can be readily seen, range from the window 26 in FIG. 2, an internal doorway 28 (FIG. 3), a portal 24 in FIG. 5, a fireplace arrangement 32 with brick embossments in FIG. 6. A plain wall 34 is shown in FIG. 4. It will also be noted that there could positioned within the respective mould 84 an electrical outlet (not shown) or switch box 37 for wall fitment (shown in dotted lines in FIGS. 3 and 6) with a conduit 39 extending there from preferably to the rebate 30 of the end panel 10 or directly below the baseboard 31 or the floor (not shown).

FIG. 2 a represents a horizontal mould 40 for the production of the end panels 8, 10 and comprises a base 41, side walls 42 with a top wall 44 and a bottom wall 46 which latter is provided with a block 30′ to produce the rebate 30 and a central boss 47 on the base 41 to form the window opening 26, as well as frame recess 29′ and baseboard recess 31′. Not illustrated in this specific case, the base 41 also includes mirror image embossments for any other formations such as bricks and the like. The walls 42 and the top wall 44 are provided with a multiplicity of slots 48 for locating and holding reinforcement rods 50 or a mesh or mat (not shown). The rods 50 for the lateral reinforcement are looped as at 14 which are held within the relevant slots and thus shielded from the concrete casting. In similar manner the longitudinal rods 50 of the reinforcement have angled ends 52 for a purpose to be described hereinafter.

Referring now to FIGS. 7 and 8, there is shown a mould jig 60 including a robust support structure 62 with a mould 64 mounted thereon. The mould 64 defines a trough 66 having a base 68 with formers in the form of upstanding sides 70, typically hingeably secured to the base with hinges 71 or the like fasteners, and shaped end walls 72 separate from but typically releasably securable to the sides 70 via mechanical fasteners 71′ or the like. Although not illustrated in this specific case, the base 68, similarly to the base 41, could also includes mirror image embossments for any desired ceiling formations such as ceiling tiles and the like. In FIG. 7 the jig 60 is illustrated with two pre-cast reinforced end walls 8, 10 located at each end of the support structure 62, which has resting beams 73 for locating and supporting the walls 8, 10 in proper relationship to the trough 66. In this latter respect, the top 68′ of each of the end panels when in the vertical orientation aligns with the base 68 of the trough 66 of the mould 64. A reinforcing steel mesh or mat 80 is laid within the confines of the trough 66 with the longitudinal rods of the mat extending to meet and to interlink with the angled ends 52 of the rods 50 in the panels 8, 10. The shaped end walls 72 are then secured in position as illustrated. The shaping of the end walls 72 is to give to the finished, pre-cast bridging panel the rebates 4 which provide the channel formation 6. As will be seen the rebates 4 are at each corner in this example and align with the loops 14 to afford a continuous guide for utility conduits (not shown). Concrete is then poured or cast into the mould 64 to embed the mat 80 in the concrete. As can be seen, there are lifting points 82 disposed within the mould 84 to provide strong lifting anchors for removing the prefabricated concrete module therefrom. It will also be noted that there is positioned within the mould 84 an electrical junction box 88 for ceiling fitment (not shown) with a conduit 90 extending therefrom to the end wall 72 to interconnect with a similar conduit 90′ already embedded in the end panel 10.

Once the concrete has gone off or set, the module 1 is lifted from the mould jig 60. As seen in FIG. 8, eyebolts 100 are screwed into the points 82 and suitable slings 101 are attached and looped onto a lifting hook 102 of a crane lift wire 104. As can be readily seen and as will be understood, the bridging panel 2 is rebated at each corner 3 to give the respective channel formation 6 aligning with the loops 14 of the reinforcements of the end panels 8, 10. The panel 8 will be seen as having a window 26 whereas the panel 8 is a plain wall 34.

The present invention thus provides a prefabricated concrete building module ready for use avoiding internal finishing and giving predetermined and designed access for utility conduits and relevant fittings. The nice internal surface finish is provided by the horizontal casting of each panel 2, 8, 10, with the internal surface facing the base 68, 41 of the respective horizontal panel mould 64, 40, as shown in FIGS. 2 a and 7. This blemish-free and smooth surface is essentially due to the fact that the air-free (because of small vibrations imposed during pouring and/or setting of concrete) concrete paste lies at the bottom of the mould 40, 64. The modules are easy to assemble together as shown in FIG. 1 a. It will readily be understood by the skilled addressee that the strength of the module will be dependent upon its disposition and the requirements of the completed building structure. Furthermore, it is only the floor which has to be formed and generally will comprise a sub-floor structure and a top finishing which may ordinary flooring, e.g. wood, ceramic etc. With the sub-floor structure utilities may be housed within the space provided thereby.

Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. 

1. A prefabricated concrete building module comprising at least two pre-cast reinforced concrete end panels, the reinforcement of the panels extending beyond the limits of the panels, a further pre-cast reinforced concrete bridging panel interconnecting said two end panels, the reinforcements of the end panels and the bridging panel being interlinked, and the bridging panel being rebated at at least one location to provide a channel registering with a part of at least one of the end panels to create a continuous guide adapted for the passage in use of utility supplies.
 2. A prefabricated concrete building module according to claim 1 wherein the bridging panel is rebated as in a right-sided notch having two sides extending through the thickness of the bridging panel orthogonally to the plane thereof.
 3. A prefabricated concrete building module according to claim 1 wherein the bridging panel is rebated at a corner.
 4. A prefabricated concrete building module according to claim 1 wherein the bridging panel is rebated at each corner.
 5. A prefabricated concrete building module according to claim 1 wherein the bridging panel is bonded to the two end panels by concrete and by the interlinking of their respective reinforcements.
 6. A prefabricated concrete building module according to claim 1 wherein each one of the bridging and the two end panels has a smooth finishing surface facing internally of the channel module.
 7. A method for the production of the prefabricated concrete building module of the first aspect, including the steps of: pre-casting at least two reinforced concrete end panels with their reinforcement extending beyond the concrete along each of two longitudinal parallel margins thereof; placing the end panels in a jig providing a generally horizontal mould of generally rectilinear open-ended trough form, with the panels disposed vertically at each end of the mould and temporarily fixed to the jig, the upper end of each panel constituting a part of the base of the trough at each end thereof; securing a former at each open end of the trough in registration with the panels to close the mould, the formers being shaped to generate in use a rebate at each corner of the nascent pre-cast bridging panel; placing a reinforcement structure in the mould; linking the reinforcement structure to the reinforcement of the prefabricated panels; providing anchor lifting points within the mould; casting concrete into the mould to cover the reinforcement structure to produce a reinforced bridging panel; and allowing the concrete to set thereby to provide a prefabricated concrete building module rebated at each corner to provide a channel.
 8. A method according to claim 7 wherein the reinforcement of the prefabricated end panels extends beyond the concrete edges in the form of loops.
 9. A method according to claim 8 wherein the loops of the reinforcement substantially align with the rebates at the corners of the pre-cast concrete bridging panel to give an elongated guide from the upper surface of the panel for the full length of the prefabricated end panels.
 10. A method according to claim 7 wherein the prefabricated end panels are manufactured in horizontal moulds to provide smooth surfaces.
 11. A method according to claim 7 wherein the prefabricated end panels are manufactured in horizontal moulds suitably dimensioned and masked to give a customized finishing.
 12. A mould according to claim 11 wherein the finishing is a window opening.
 13. A mould according to claim 11 wherein the finishing is a portal.
 14. A prefabricated concrete building module produced in accordance with claim
 7. 15. A building structure comprising a plurality of prefabricated concrete building modules according to claim
 1. 